Method of assembling displays on substrates

ABSTRACT

Various embodiments of methods and systems for designing and constructing displays from multiple light-modulating elements are disclosed. Display elements having different light-modulating and self-assembling characteristics may be used during display assembly and operation.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to, claims the earliest availableeffective filing date(s) from (e.g., claims earliest available prioritydates for other than provisional patent applications; claims benefitsunder 35 USC §119(e) for provisional patent applications), andincorporates by reference in its entirety all subject matter of thefollowing listed application(s); the present application also claims theearliest available effective filing date(s) from, and also incorporatesby reference in its entirety all subject matter of any and all parent,grandparent, great-grandparent, etc. applications of the followinglisted application(s):

-   -   1. United States patent application entitled ELEMENTS FOR        SELF-ASSEMBLING DISPLAYS, naming W. Daniel Hillis, Nathan P.        Myhrvold, Clarence T. Tegreene, Lowell L. Wood, Jr., and        Victoria Y. H. Wood as inventors, filed Mar. 11, 2005.    -   2. United States patent application entitled SELF-ASSEMBLY OF        ELEMENTS FOR DISPLAYS, naming W. Daniel Hillis, Nathan P.        Myhrvold, Clarence T. Tegreene, Lowell L. Wood, Jr., and        Victoria Y. H. Wood as inventors, filed Mar. 11, 2005.    -   3. United States patent application entitled SELF ASSEMBLING        DISPLAY WITH SUBSTRATE, naming W. Daniel Hillis, Nathan P.        Myhrvold, Clarence T. Tegreene, Lowell L. Wood, Jr., and        Victoria Y. H. Wood as inventors, filed substantially herewith.    -   4. United States patent application entitled SUPERIMPOSED        DISPLAYS, naming W. Daniel Hillis, Nathan P. Myhrvold,        Clarence T. Tegreene, and Lowell L. Wood, Jr. as inventors,        filed ______.

TECHNICAL FIELD

The present application relates, in general, to the field of displays,and particularly to methods of manufacture thereof.

BACKGROUND

Displays used in television screens, computer monitors, electronic signsor displays, and the like may be formed from arrays of large numbers oflight-emitting elements that may be controlled to display time-varyingpatterns of light. Color displays typically include light-emittingelements that emit light of several colors. Displays commonly includeelements capable of emitting red, green, or blue wavelengths(corresponding to the color sensitivities of the photoreceptors in thehuman eye), since by adjusting the intensity of the three colorsappropriately, any color in the visible spectrum can be represented tothe human eye.

SUMMARY

Embodiments of methods and systems for self-organization and assembly ofdisplay elements with substrates to form displays are disclosed herein.Features of various embodiments will be apparent from the followingdetailed description and associated drawings.

BRIEF DESCRIPTION OF THE FIGURES

Features of the invention are set forth in the appended claims. Theexemplary embodiments may best be understood by making reference to thefollowing description taken in conjunction with the accompanyingdrawings. In the figures, like referenced numerals identify likeelements.

FIG. 1 illustrates an embodiment of a display element array;

FIG. 2 depicts a method of forming an embodiment of the display elementarray;

FIG. 3 illustrates a method of forming an embodiment of a displayelement array;

FIG. 4 illustrates a method of disposing display elements on asubstrate;

FIG. 5 depicts a further method of disposing display elements on asubstrate;

FIGS. 6A-6C illustrates distribution display elements to receptorlocations on a substrate;

FIGS. 7A-7C illustrate distribution of a first set of display elementsto receptor locations on a substrate;

FIG. 8 illustrates removal of excess display elements from of asubstrate;

FIG. 9 illustrates an alternative method of removing excess displayelements from a substrate;

FIGS. 10A-10C illustrates distribution of a second set of displayelements to receptor locations on a substrate;

FIG. 11 is a flow diagram illustrating a method of assembling a displayelement array;

FIG. 12 depicts two display elements mounted in receptor locations on asubstrate;

FIG. 13 illustrates a substrate having multiple receptor locations andcorresponding display elements;

FIG. 14 illustrates the display elements of FIG. 13 mounted on receptorlocations on the substrate of FIG. 13;

FIG. 15 illustrates several types of display elements attached tocorresponding receptor locations on a substrate;

FIG. 16 depicts exemplary embodiment of a display element;

FIG. 17 depicts another exemplary embodiment of a display element;

FIG. 18 depicts another exemplary embodiment of a display element;

FIG. 19 illustrates a display element including two light-emittingelements;

FIG. 20 illustrates a display element formed from three displaysub-elements;

FIG. 21 illustrates a substrate including irregularly distributedreceptor locations;

FIG. 22 depicts testing of an assembled display element array;

FIG. 23 is a flow diagram of a process for configuring a display elementarray;

FIG. 24 illustrates a method for configuring a display element array;

FIG. 25 depicts an embodiment used in a computer monitor;

FIG. 26 depicts an embodiment used in a television screen;

FIG. 27 depicts an embodiment used in an electronic sign;

FIG. 28 depicts an embodiment used in an item of apparel;

FIG. 29 depicts an embodiment used in a decorative object;

FIGS. 30A-30D illustrate the manufacture of a display having severalregions;

FIG. 31 illustrates distribution of display elements on several regionsof a substrate;

FIG. 32A-32B illustrate sequential distribution of display elements on asubstrate;

FIG. 33A-33C illustrate the replacement of a defective display element;and

FIG. 34 shows a process for detecting and replacing a defective displayelement.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. The detaileddescription and the drawings illustrate specific exemplary embodimentsby which the invention may be practiced. These embodiments are describedin sufficient detail to enable those skilled in the art to practice theinvention. It is understood that other embodiments may be utilized, andother changes may be made, without departing from the spirit or scope ofthe present invention. The following detailed description is thereforenot to be taken in a limiting sense, and the scope of the presentinvention is defined by the appended claims.

Throughout the specification and claims, the following terms take themeanings explicitly associated herein unless the context dictatesotherwise. The meaning of “a”, “an”, and “the” include pluralreferences. The meaning of “in” includes “in” and “on.” A reference tothe singular includes a reference to the plural unless otherwise statedor inconsistent with the disclosure herein.

According to an exemplary embodiment, a display is constructed that hasa plurality of display elements located at a plurality of receptorlocations on a substrate. Each display element may include alight-modulating element of a respective type, carried by a carrierhaving respective shape, size or surface characteristics. Displayelements may have shape, size or surface characteristics complementaryto the shape, size or surface characteristics of certain receptorlocations on the substrate, to promote self-assembly of display elementsto selected receptor locations. Display elements containinglight-modulating elements of like types are characterized by like shape,size or surface characteristics. Accordingly, display elementscontaining specific types of light-modulating elements self-assemble tothe substrate at selected locations, to form a display having a desiredarrangement of light-emitting elements. Light-modulating elementsinclude elements which modulate light perceived by a viewer of thedisplay. In some embodiments, light-modulating elements may belight-emitting elements. In other embodiments, light-modulating elementsmodify or modulate light incident on the display to present a modifiedview to the viewer by, for example, absorbing, reflecting, diffracting,or scattering light, or by fluorescing or performing some other type offrequency conversion. Although specific types of light-modulatingelements may be referenced in connection with certain exemplaryembodiments described herein, unless it is stated that a particular typeof light-modulating element is required for use in a particularembodiment, it should be assumed that other types of light-modulatingelements may be used in the embodiment as well.

FIG. 1 depicts an exemplary embodiment of a display element array 10including a substrate 20 and a plurality of display elements 30 and 32mounted in corresponding receptor locations 40 and 42, respectively. Inthe example of FIG. 1, display elements 30 are a first type of displayelements and display elements 32 are a second type of display element.The display may include a substrate 20 having a first plurality ofreceptor locations of first type 40 and a second plurality of receptorlocations of second type 42, which are adapted to receive displayelements 30 and 32, respectively, arranged in a regular, repeatingpattern according to type, as depicted in FIG. 1.

A method of constructing a display element array as illustrated in FIG.1 is outlined generally in FIG. 2. At step 52, a plurality of displayelements, each of which includes a light-modulating element, is disposedon a substrate. At step 54, relative motion is induced between thedisplay elements and the substrate sufficient to cause at least aportion of the display elements to distribute to receptor locations onthe substrate. At step 56, display elements distributed to receptorlocations on the substrate are secured in fixed relationship withrespect to each other. At step 58, connections are established forproviding control signals to secured display elements to drive emissionof light by the secured display elements.

Disposing a plurality of display elements on the substrate may includedisposing a first subset of display elements and a second subset ofdisplay elements on the substrate. Each display element in the firstsubset may include a light-modulating element of a first type containedin a carrier having a first shape, size or surface characteristic, andeach display element in the second subset may include a light-modulatingelement of a second type contained in a carrier having a second shape,size or surface characteristic. The substrate may include a first subsetof receptor locations having a first complementary shape, size orsurface characteristic that facilitates distribution of display elementsof the first subset to the first subset of receptor locations, and asecond subset of receptor locations having a second complementary shape,size or surface characteristic that facilitates distribution of displayelements of the second subset to the second subset of receptorlocations.

A further exemplary method of display element array construction isdescribed in FIG. 3. At step 72, a substrate is provided having aplurality of receptor locations each having a respective defined shape,size and surface characteristic. At step 74, a plurality of displayelements, each having a respective defined shape, size and surfacecharacteristic complementary to a shape, size and surface characteristicof at least one receptacle are introduced onto the substrate. Displayelements containing light-modulating elements of like types arecharacterized by like shapes, sizes and surface characteristics.Relative motion is induced between the display elements and thesubstrate sufficient to cause at least a portion of the display elementsto be distributed to receptacles of complementary shape and size on thesubstrate at step 76. At step 78, display elements distributed intoreceptacles of complementary shape, size and surface characteristic onthe substrate are connected to the substrate.

First and second types of receptor locations (and corresponding displayelements), as depicted in FIG. 1, may have one or more respective shape,size, surface, or other characteristics. Each receptor location of thefirst type may have a first surface characteristic, and each receptorlocation of the second type may comprise a second surfacecharacteristic. A display may also comprise a plurality of displayelements of the first type mounted on the substrate at the firstplurality of receptor locations, and a plurality of display elements ofthe second type mounted on the substrate at the second plurality ofreceptor locations. Each display element of the first type comprises asurface characteristic adapted to operate cooperatively with the firstsurface characteristic on the first type of receptor location tofacilitate self-assembly of the first display element type with thefirst receptor location type, and each display element of the secondtype includes a surface characteristic adapted to operate cooperativelywith the second surface characteristic on the second type of receptorlocation to facilitate self-assembly of the second display element typewith the second receptor location type. Display elements of the firsttype may emit light that differs from light emitted by display elementsof the second type by one or more parameters including wavelength bandenvelope, spectral width and/or content, power, spatial or temporalemission pattern/pulse format, direction of emission, intensity,brightness, irradiance, polarization, response speed, or linearity.

Display elements may be disposed on a substrate by various methods. FIG.4 illustrates an exemplary method of disposing display elements 30 and40 onto substrate 20. In the embodiment of FIG. 4, display elements 30and 40 are poured onto substrate 20 from dispenser 80. As used herein,‘pouring’ refers to a process by which multiple display elements 30 and40 are moved onto substrate 20 from a container or dispenser 80 by meansof gravity or other means of inducing a body force on them or a bulkacceleration of them. FIG. 5 illustrates another method of disposingdisplay elements 30 and 40 onto substrate 20 by spraying. As usedherein, ‘spraying’ refers to a process by which display elements areejected from container or dispenser via pressure, e.g., via spray nozzle90. Spray nozzle 90 may be configured to disperse display elements 30and 40 over substrate 20. In the embodiments depicted in FIGS. 4 and 5,display elements may be mixed into a carrier liquid and applied in theform of a slurry, emulsion, suspension, colloid or gel, or fluidized bythe addition of a gas. They may also be disposed onto the substratewithout being mixed into a carrier liquid or gas. Note that although twotypes of display elements, 30 and 40, are depicted in the presentexemplary embodiments, in other embodiments, one, two, three, or moredifferent types of display elements may be used, and the methodsdescribed herein may be suitable in embodiments including variousnumbers of types of display elements.

After display elements are disposed on a substrate, they mayself-assemble into preferred receptor locations, as determined by theirrespective surface or shape characteristics. In some embodiments,movement of display elements into preferred receptor locations isenergetically favored. In some cases, surface or shape characteristicsmay produce sufficiently strong attractions between display elements andpreferred receptor locations that they self-assemble into a preferredarrangement on the substrate without further input of energy. In manycases, however, input of energy (e.g., an activation energy) may berequired to cause display elements to move into their preferred receptorlocations. Energy may be input to the display elements by impartingrelative motion between display elements and substrate, e.g. by shakingor vibrating the substrate. Display elements may then move with respectto each other until they eventually move into preferred receptorlocations. Other forms of activation energy (e.g., light, heat, chemicalenergy) may also be used to promote distribution of display elementsinto preferred receptor locations. Each of the activation energies maybe applied independently or a plurality of forms of activation energiesmay be applied in combination. The method may include controlling anenvironmental condition to promote distribution of the display elementsto receptor locations on the substrate.

In order to promote self-assembly of display elements into receptorlocations, relative movement of the multiple display elements and thesubstrate may be induced. Such movement may be imparted, for example, byshaking or vibration of the substrate. The movement may cause thedisplay elements to distribute into a single layer on the substrate.Relative movement of the display elements and the surface may be inducedby shaking or vibrating the surface, or by otherwise moving the surface.The induced movement may be random or substantially random. The movementmust be sufficient to move display elements relative to other displayelements in order to cause display elements to come into proximity andhave opportunity for interaction and/or association with displayelements of various types. The pattern of shaking or vibration may bemodified over time; e.g., more vigorous movement may be used to causedisplay elements to form a single layer, while movement that is gentler(or of a different frequency, direction, etc.) may be more effective forpromoting associations of display elements within a single layer.Depending on the size and type of display elements and substrate,various methods of imparting motion and/or interaction between displayelements and substrate may be used, and the embodiments depicted hereinare only examples.

As shown in FIG. 6A, display elements 30 and 40 disposed on substrate 20may not initially be distributed over substrate 20 in a single layer. Insome regions (e.g., region 92 in FIG. 6A), display elements may be piledon other display elements in two or more layers. In many cases, it ispreferred that display elements distribute into a single layer onsubstrate 20. Distribution of display elements into a single layer maybe aided by gravity as well as by induced movement between displayelements and surface. In certain embodiments, distribution of displayelements into a single layer may be aided by repulsion of one or moresurfaces of the display element from the substrate surface. Suchrepulsion may take place, for example, because of surface energyeffects, surface magnetic properties, and the like, due to suitabletreatment of display elements and substrate surfaces. At the stepdepicted in FIG. 6B, shaking or vibrating substrate 20 may cause displayelements 30 and 40 to disperse further to form a single layer of displayelements on substrate 20. Further shaking or vibration may be applied tocause display elements 30 and 40, already distributed in a single layeron substrate 20, to move into appropriate receptor locations 32 and 42,respectively, to form display element array 100 as shown in FIG. 6C. Ifdisplay elements 30 and 40 are small enough and have suitable shape andsurface characteristics, their behavior may be powder- or fluid-like. Inorder to facilitate the distribution of display elements 30 and 40 ontosubstrate 20, display elements may be mixed into a fluid or fluidizedmedium, and applied to substrate 20 as a slurry, emulsion, suspension,colloid, or gel. Movement of display elements 30 and 40 on substrate 20may also be facilitated by various mechanical spreaders, stirrers, etc.,instead of or in addition to shaking, vibration, or other methods ofimparting energy to the display elements and/or substrate.

One method of assembling display elements of two different types intorespective receptor locations on a substrate makes use of a two-stageprocess. During the first stage of the process, illustrated in FIGS.7A-7C, a first type of display elements is assembled into a first typeof receptor locations on a substrate. As depicted in FIG. 7A, asubstrate 110 is provided which includes first receptor locations 120,which are of a first type, and second receptor locations 122, which areof a second type. In the exemplary embodiment depicted in FIG. 7A,receptor location 120 and 122 are circular receptacles of differentsizes, with receptor locations 120 being larger than receptor locations122. A first set of display elements made up of a first type of displayelements 130 is disposed on substrate 110. Display elements 130 have asize and shape complementary to first receptor locations 120. Displayelements 130 are too large to fit into second receptor locations 122. Instep 7B, relative motion may be induced between display elements 130 andsubstrate 110, for example by shaking or vibrating substrate 110. Therelative motion is sufficient to cause display elements 130 to selfassemble into respective receptor locations 120, as shown in FIG. 7C.Display elements 130 in excess of the number needed to fill receptorlocations 120 may remain on the surface of substrate 110.

The method may include removing display elements that have notdistributed into receptacles on the substrate from the substrate.Removing display elements may include removing display elements notdistributed into receptacles of complementary shape, size, and surfacecharacteristic on the substrate from the substrate prior to connectingdisplay elements that have distributed into receptacles. Displayelements may be removed from the substrate by moving or accelerating thesubstrate, for example, by shaking or by tipping the substrate, asdepicted in FIG. 8. In other embodiments, display elements may beremoved from the substrate by applying a fluid to the substrate, e.g.,by rinsing it. Display elements may also be removed from the substrate110 by applying motive force to the display elements, for example, witha scraper 131, as depicted in FIG. 9. Display elements removed from thesubstrate may be recovered for later use.

In the second stage of the two-stage process, as depicted in FIGS.10A-10C, a second type of display elements 132 are distributed intosecond receptor locations 122 on substrate 110. FIG. 10A illustratessubstrate 110, with first receptor locations 120 filled with firstdisplay elements 130, and receptor locations 122 vacant. As illustratedin FIG. 10B, after a second set of display elements 132 is distributedonto substrate 110, relative motion is induced between substrate 110 anddisplay elements 132 sufficient to cause display elements 132 toself-assemble to their respective receptor locations 122. FIG. 10Cdepicts substrate 110 with all receptor locations 120 and 122 filled,and several excess display elements 132 resting on top of substrate 110.Excess display elements can be removed by various methods, including,but not limited to, those depicted in FIGS. 8 and 9.

As illustrated in FIGS. 7A-10C, receptacles 120 are complementary todisplay elements 130, which are of a first size and shape, andreceptacles 122 are complementary to display elements 132, which are ofa second size and shape. Display elements 130 in the first set areconfigured to have a probability of fitting into receptacles 122 that islower than the probability of display elements 132 fitting intoreceptacles 120. Various display element/receptor location combinationsmay be devised in which the one type of display element has a relativelyhigher probability of distributing into the incorrect receptor locationthan does the other. Therefore, assembly of display elements into theappropriate locations can be improved by introducing the differentdisplay elements in a specified order, with those having the lowestprobability of distributing into an incorrect receptor location beingintroduced earliest in the process. This approach may be extended todisplays that include more than two types of display elements andreceptor locations. In some embodiments, display elements of the firstsize and shape are of a different size, but substantially the same shapeas display elements of the second size and shape. In other embodiments,display elements of the first size and shape are of a different shape,but substantially the same size as display elements of the second sizeand shape. In some embodiments display elements of the first size andshape may be larger than display elements of the second size and shape.Display elements in the first set may include light-modulating elementsthat are of a different type than light-modulating elements in displayelements in the second set. In some embodiments, display elements in thefirst set may include light-modulating elements capable of emittinglight in a first wavelength band and display elements in the second setmay include light-modulating elements capable of emitting light in asecond wavelength band.

In certain embodiments, the display elements from at least one of thefirst set and the second set may be connected to the substrate by atleast one of heat, vibration, pressure, electrostatic or magnetostaticforce, a chemical, radiation, or an adhesive. In some embodiments,connecting display elements to the substrate may include makingelectrical or optical connections between the display elements and thesubstrate. Display elements may also be connected to adjacent displayelements. In some embodiments, display elements may be connected toadjacent display elements via the substrate, by forming electrical oroptical connections between display elements and the substrate.

FIG. 11 is a flow diagram outlining a method of forming a display withtwo types of display elements by introducing the two types of displayelements to the substrate in sequence. An example of this type ofprocess is depicted in FIGS. 7A-10C. The first type of display elementshas a first shape, size or surface characteristic, and the second typeof display elements has a second shape, size or surface characteristic.The substrate may have a first plurality of receptor locations and asecond plurality of receptor locations, having first and secondcomplementary shape, size or surface characteristics, respectively. Themethod of forming a display may include introducing a first set ofdisplay elements each having a first shape, size or surfacecharacteristic and including a light-modulating element of a first typeonto a substrate, as shown at step 152. At step 154, relative motion isinduced between the display elements in the first set and the substrate.The motion may be sufficient to cause at least a portion of the displayelements in the first set to distribute into a first plurality ofreceptor locations on the substrate. At step 156, display elements inthe first set that have not distributed into receptor locations in thefirst plurality of receptor locations are removed from the substrate. Asecond set of display elements having a second shape, size or surfacecharacteristic and including a light-modulating element of a second typeis then introduced onto the substrate at step 158. At step 160, relativemotion is induced in the display elements in the second set and thesubstrate. The motion may be sufficient to cause at least a portion ofthe display elements in the second set to distribute into a secondplurality of receptor locations on the substrate. At step 162, displayelements in the second set that have not distributed into receptorlocations in the second plurality of receptor locations are removed fromthe substrate. Finally, at step 164 display elements distributed intoreceptor locations on the substrate are connected to the substrate.

Design of display elements and substrate for constructingself-assembling display element arrays may include designing substratesto operate in cooperation with display elements. Display elements may beattached to the substrate, or, in some embodiments, may simply rest uponand be supported by the substrate. The substrate may have a surfacecharacteristic or property that interacts with a surface characteristicof at least some of the display elements to influence the orientation ofdisplay elements on the surface or distribution of display elements onthe surface. Surface characteristics that may influence the orientationof display elements may include, but are not limited to, electrostaticor magnetostatic charge, surface energy, magnetic, shape or texturecharacteristics. The surface characteristic may be the binding affinityof one or more organic molecules and specifically biomolecules, coatedon or adhered to the surface. The substrate may include electricalcircuitry and contacts for sending power or data signals to one or moredisplay elements disposed on its surface. The substrate may includeoptical circuitry and optical connections to display elements on itssurface. Choice of substrate is strongly dependent on the intendedapplication of the display element array, though general designprinciples apply to substrate and display elements across applications.

In some embodiments, the substrate may include a planar surface. Atleast a portion of the receptor locations may be receptor locationsformed in the planar surface. In other embodiments, the substrate mayinclude a non-planar surface. The substrate may include a plurality ofaddress lines, and each display element of the plurality of displayelements may be independently addressable through one or more of theplurality of address lines. Characteristics of the receptor locationsand display elements may include shape and or surface characteristics,including, for example, one or more of charge characteristics, surfaceenergy characteristics, or electrical or magnetic characteristics.

Display elements used in various embodiments may be made up of one ormore light-modulating elements, and a carrier which houses, supports,contains, or surrounds the light-modulating element(s). A displayelement suitable for assembly into multicolor displays having aplurality of elements may include a light-emitting element capable ofemitting light in respective spectral range corresponding to one or moreof the colors of the display and a carrier in which the light-emittingelement is housed. The carrier may be characterized by at least onesurface, shape or size characteristic, or a combination of shape, sizeand surface characteristics. Self-assembly of display elements intocorresponding receptor locations may be based upon variations in asingle characteristic (e.g., only size, only surface charge, etc.) or itmay be based upon a combination of shape, size, and/or surfacecharacteristics. The carrier thus provides the surface, shape or sizecharacteristics that are characteristic of the display element. Thecarrier may have defined shape, size or surface characteristics,selected to preferentially locate the display element with respect toother display elements on the substrate in a desired color pattern toform a multicolor display.

Various types of display elements may be used in the differentembodiments. Display elements may include light-emitting elements insome embodiments. In some embodiments, display elements may includeother forms of light-modulating elements having light spectralcharacteristic, and not limited to light-emitting elements. For example,other types of display elements may absorb, reflect, diffract, scatter,fluoresce, or otherwise modify light impinging on the display to providea particular visually detectable effect on the display, in which casedisplay elements have a characteristic light absorption spectrum, lightreflection spectrum, etc., instead of or in addition to a light emissionspectrum.

Display elements may be distinguished from each other by variouscharacteristics, of which the following are only exemplary: intensity ofemitted light, power consumption, size, shape, wavelength band envelope,spectral width, spectral content, power, intensity, brightness,irradiance, emission pattern, direction of emission, polarization,response speed, and linearity. Moreover, display elements may have acharacteristic spectral response that is not based upon light emission,but rather upon some form of light modulation, including, but notlimited to, light reflection, refraction, absorption, or scattering.Display elements may include various types of light-emitting or-modulating elements. Each type of light-emitting element may be capableof emitting light in a respective wavelength band. Light-emittingelements may be, for example, inorganic wavelength converters, organicwavelength converters, phosphors, fluors, laser diodes, light-emittingdiodes, organic light-emitting diodes, polymer light-emitting diodes,quantum dots, polymers, polymer, electroluminescent devices,chemiluminescent devices, or nonlinear optical materials. Each displayelement may include a polymeric carrier or a silicon-based carrier.Light-emitting elements may be capable of emitting light in a wavelengthband corresponding to one or more colors, responsive to a controlsignal. Light-modulating elements may include structures includingnematic crystals and polarizers, such as those found in LCDs,photoabsorptive materials, MEMS structures, optical polymers, or othertypes of elements that can vary the amplitude, polarization, colorcontent, pulse-duration or pulse-format, overall energy or other aspectsof the light.

In some embodiments, a display may include display elements includingtwo different light-emitting elements that emit light in the samegeneral wavelength band, for example two light-emitting elements thatemit red light: one emitting light in a narrow wavelength band and oneemitting light in a broad wavelength band. Display elements in the firstset may include light-emitting elements that emit light that differsfrom light emitted by light-emitting elements in display elements in thesecond set by one or more parameters including wavelength band envelope,spectral width, power, emission pattern, polarization, response speed,or linearity.

Association and/or assembly of display elements with respect to receptorlocations on a substrate, and, in some cases, with other displayelements, may be dependent on macro and microscale shape and surfaceproperties. Shape characteristics such as concavities, convexities, orvarious combinations thereof may be used to promote self-assembly, asdescribed in U.S. Pat. No. 6,507,989; Srinivasan et al., J.Microelectromechanical Systems, Vol. 10, No. 1, pp. 17-24, March 2001;Zheng et al.; Proc. Natl. Acad. Sci., Vol 101, No. 35, pp. 12814-12817,Aug. 31, 2004; and Whitesides and Grzybowski, Science Vol. 295, pp.2418-2421, Mar. 29, 2002; all of which are incorporated herein byreference. Other configurations that may promote self-assembly alone ortogether with other properties herein include overall size, othergeometrical aspects, or weight distributions, or other physicalvariations. Surface characteristics that promote self-assembly includebut are not limited to charge or surface energy properties, electric ormagnetic properties, or binding affinities, as discussed in Bowden etal., J. Am. Chem. Soc., Vol. 121, pp. 5373-5391, 1999 and Srinivasan etal., J. Microelectromechanical Systems, Vol. 10, No. 1, pp. 17-24, March2001; both of which are incorporated herein by reference. Suchproperties may be conferred on a surface by molecules bound or otherwiseadhered or applied to the surface. Properties that have an effect at thesurface may also be internal properties of a display element; e.g., asurface magnetic field may be produced by magnetized structures within adisplay element. Molecular structures may promote association orinteractions including charge interactions, hydrogen bonding, molecularbonding, or other molecular interactions. The surface may, for example,be coated with organic molecules and specifically with biomoleculeshaving specific binding affinities. Selective interactions ofbiomolecules to other biomolecules or to non-biological moleculesincluding, but not limited to, base pairing of complementary nucleicacid/nucleotide sequences, amino acid and/or protein-proteininteractions, saccharide sequence or glycoprotein interactions,antibody-antigen interactions, and combinations thereof, may be employedin some embodiments, as described in Montemagno and Bachard;Nanotechnology, Vol. 10, pp. 225-231, 1999; Chung et al., Small, Vol. 1,pp. 1-5, 2005; and Jakab et al., Proc. Natl. Acad. Sci. Vol 101, No. 9,pp. 2865-2869, Mar. 2, 2004, all of which are incorporated herein byreference. For the purpose of promoting self-organization, interactionsor associations between display elements and receptor locations on asubstrate may range from relatively weak to relatively stronginteractions or associations. Individual display elements may have bothdistinctive shape and surface properties selected to promote theformation of preferred associations with receptor locations and/ordisplay elements with a degree of preference that depends upon the typeof display element. Methods of assembling display elements to receptorlocations on a substrate may include controlling an environmentalcondition to promote distribution of display elements to desiredreceptor locations on the substrate.

According to one preferred embodiment, display elements may have arespective shape, size or surface characteristic and include alight-emitting element capable of emitting light of a characteristicwavelength band. The respective shape, size or surface characteristic isadapted to cause each display element to associate with receptorlocations on the substrate with a degree of preference that depends uponthe type of display element. In certain embodiments, display elementshave one or more respective shape, size or surface characteristics thatare selected to provide a relatively lower preference for receptorlocations of certain types and higher preference with receptor locationsof other types.

The display element may include one or more inputs for receiving powerand/or control signals. For example, the display element may include atleast one contact for forming an electrical or optical connection with asubstrate or another display element to receive power or controlsignals. In some embodiments, the display element may include a radiotransmitter and/or receiver for sending or for receiving an RF controlor data signal. The display element may include a power signal inputthat may be, for example, a receiver coil or antenna for receivingelectromagnetic power. In some embodiments, display elements may includevarious other structures that convert energy or power received fromexternal sources to light, including, for example, photovoltaic,fluorescent, and chemiluminescent devices. In some embodiments, thedisplay element may include a power source, which may be a battery orother power-generating, -collecting, -transducing or -accumulatingdevice or structure, such as a photovoltaic cell, an inductive coil, anantenna, or an energy-scavenging device.

Control signals for controlling generation or modulation of light by adisplay element may be transmitted to display elements via the substrateor one or more adjacent display elements via data-links such asacoustic, optical, magnetic or electrical links. Display elements mayinclude a transceiver that allows data and control signals to be sentbetween display elements and external control circuitry, withoutelectrical connections between display elements. Display elements may beresponsive to control signals in the form of electrical orelectromagnetic energy (e.g., UV light or an electron beam) targeted onthe display element. Display elements may emit light in response to anelectrical control signal (e.g., current or voltage), an electromagneticcontrol signal (e.g., an electron beam or incident light), or othercontrol signal. A display element may emit light in response to acontrol signal. In some embodiments, a display element may turn off inresponse to the control signal, while in still other embodiments, thepattern of light emission or modulation produced by a display elementmay be modulated by a control signal; e.g., the amplitude or pulsefrequency of emitted light may be modified in response to a controlsignal.

Each display element may include a unique identifier. Each displayelement may be capable of storing identifying information. The uniqueidentifier may be a number or code stored in various formats detectableor readable by external devices and/or by other components within thedisplay. For example, the unique identifier may be an RFID or other typeof electromagnetically responsive element. The unique identifier may bea pattern of bits stored in any of various types of data storageelements in or on the display element, for example, in electronic,optical, or magnetic form. In some embodiments, the identifyinginformation may be updatable, for example, by circuitry on the displayelement, by a control signal sent from the substrate, or by a controlsignal sent from a location remote from the substrate. The identifyinginformation may include address information specifying the location ofthe display element on the substrate.

According to various embodiments, display elements include a carrierwhich contains or surrounds one or more light-modulating elements andmay confer upon the display element its shape, size or surfacecharacteristics. The carrier may include a polymeric material or asemiconductor material. The light-modulating element may be formedintegrally with the carrier or may be formed separately from the carrierand subsequently embedded in the carrier. The carrier may include atleast one shape, size or surface characteristic, which may include abinding affinity of an organic molecule and specifically a biomolecule(including but not limited to binding or interactions of one or more ofan amino acid sequence, saccharide sequence, nucleic acid sequence,protein, or glycoprotein, and combinations thereof), a surface energycharacteristic, or an electric or magnetic characteristic. The carriermay include an electric or a magnetic characteristic complementary to anelectric or a magnetic characteristic of a respective receptor location.The shape or surface characteristic of the carrier may include a surfaceelectric or magnetic signature complementary to a surface electric ormagnetic signature of a corresponding receptor location.

The carrier may include at least one control signal input, which mayinclude an electrical contact. Alternatively, the control signal inputmay include an optical or an acoustic connection. The carrier mayinclude a radio receiver or transceiver for receiving an RF controlsignal. It may also include a power input, which may include, forexample, an electrical contact or a coil or antenna for receiving anelectromagnetic power signal. The carrier may include one or more of abattery, a receiver, a transmitter, an analog or analog-digital hybridpower-control device, or a microprocessor.

Formation of display elements may include multi-step processes,including a separate step of applying or forming a surfacecharacteristic on one or more selected regions of the carrier. This stepmay be performed before or after the carrier and light-modulatingelement have been joined together. Methods of applying or formingsurface characteristics may themselves be multi-step processes (e.g.,methods of attaching biomolecules to surfaces as referenced inMontemagno and Bachard Nanotechnology, Vol. 10, pp. 225-231, 1999; Chunget al., Small, Vol. 1, pp. 1-5, 2005; Published U.S. Patent ApplicationUS 2004/0023414 A1; and U.S. Pat. No. 6,809,196, all of which areincorporated herein by reference).

In some embodiments, a method of designing displays includes selecting aset of light-emitting elements, each of which is capable of emittinglight of respective selected wavelength, determining a preferredarrangement of the light-emitting elements, and designing a substratehaving corresponding receptor locations in a pattern or configurationselected to cause display elements to assemble onto the substrate in thepreferred arrangement. It should be noted that, while reference is madeto “light-emitting” elements, in some embodiments, elements which modifylight in some other way to produce a visually-detectable effect (e.g.,by light reflection, refraction, or absorption or via fluorescence orother type of frequency-conversion) may be used in place oflight-emitting elements. The preferred arrangement specifies theposition of light-emitting elements capable of emitting light of each ofsaid selected wavelength bands relative to light-emitting elementscapable of emitting light of other selected wavelength bands. Designingdisplays further includes designing an attribute set for each displayelement, where each attribute set is adapted to promote self-assembly ofthe display elements onto their respective receptor locations on thesubstrate, according to the preferred arrangement. The set of displayelements according to the method may include a plurality of types oflight-emitting elements, in which each type of display element ischaracterized by a respective attribute set and is capable of emitting(or modulating) light of a respective selected wavelength band. Eachdisplay element type may include a light-modulating element capable ofemitting (reflecting, diffracting, scattering, etc.) light in arespective wavelength band, and each display element type may becharacterized by a respective shape, size, or surface characteristic. Insome embodiments, each display element type may have a differentrespective combination of shape, size, and surface characteristic, thaneach other display element type.

The preferred arrangement of display elements in the display elementarray may include a pattern having short-range order, a repeatingpattern, or a pattern having long-range order. Patterns having eithershort-range order or long-range order may incorporate repeatingpatterns. In an embodiment particularly suited for the design ofthree-color displays, such as are commonly used in television orcomputer screens, three distinct types of display elements may be used.A repeating pattern unit may include at least one red display element,at least one green display element, and at least one blue displayelement.

In some exemplary embodiments, a display element set may include a firstset of light-emitting portions having a first wavelength response and afirst set of body portions, each carrying a respective one or more ofthe light-emitting portions in the first set of light-emitting portions.Each body portion in the first set of body portions may have a firstdefined physical feature corresponding to the first wavelength response.The set of display elements may also include a second set oflight-emitting portions having a corresponding second wavelengthresponse and a second set of body portions, each carrying a respectiveone or more of the light-emitting portions in the second set oflight-emitting portions. Each body portion in the second set of bodyportions may have a second defined physical feature corresponding to thesecond wavelength response. The first defined physical feature isconfigured to preferentially associate with a first receptor locationtype on a substrate, and the second defined physical feature isconfigured to preferentially associate with a second receptor locationtype on the substrate.

FIG. 12 illustrates one exemplary method of connecting display elementsto a substrate and providing signals for activating the displayelements. A first display element 200 and a second display element 202are mounted in substrate 204 in first receptor location 206 and secondreceptor location 208, respectively. In this example, first receptorlocation 206 and second receptor location 208 are recessed regions orreceptacles formed in substrate 204. Display element 200 includeslight-emitting element 210. Contacts 212 and 214 in display element 200provide for the delivery of power and control signals to light-emittingelement 210. Contact 212 and contact 214 form connections with contacts216 and 218, respectively, which are formed in receptor location 206 andconnected to power line 220 and control line 222. Similarly, displayelement 202 includes light-emitting element 230 and contacts 232 and234, which provide for the delivery of power and control signals tolight-emitting element 230. Contact 232 and contact 234 form connectionswith contacts 236 and 238, respectively, which are formed in receptorlocation 208 and connected to power line 240 and control line 242.

The distribution of specific types of display elements in the displayelement array may be determined by the distribution of correspondingreceptor location on the substrate, e.g., specific types of receptorlocations may be distributed in a regular and/or repeating pattern, asdepicted in the embodiment of FIG. 1. In several previously describedembodiments, receptor locations on the substrate are recessed regions orreceptacles having a size, shape or surface characteristic matched tothe shape, size or surface characteristic of a corresponding type ofdisplay element. The receptor locations may be spaced apart from eachother so that there is no contact between adjacent display elements. Inother embodiments, receptor locations may be located immediatelyadjacent to each other. In some embodiments, display elements andsubstrate may be configured so that it is possible to form connectionsbetween display elements positioned in adjacent receptor locations.

FIGS. 13 and 14 illustrate an exemplary embodiment in which displayelements are located immediately adjacent to each other. In FIG. 13,substrate 250 includes first receptor location type 252 and secondreceptor location type 254, which are designed to receive first displayelement type 260 and second display element type 262, respectively. FIG.14 depicts display elements 260 and 262 mounted in respective receptorlocations 252 and 254 in substrate 250. Also depicted are connections270 between adjacent display elements. Connections between adjacentdisplay elements may provide mechanical strength and/or rigidity, mayprovide for the transfer of thermal energy for heating or cooling, e.g.,to provide a desired thermal environment, or may be electrical oroptical connections that permit the transfer of information, control orpower signals between display elements.

In some embodiments, receptor locations may not be recessed areas.Receptor locations may be regions on a substrate surface having aparticular surface characteristic or property. Association of displayelements may be based upon surface interaction rather than upon matchingof size or shape characteristics. In other embodiments, matching ofdisplay elements to receptor locations may be based upon a combinationof size, shape and surface characteristics or properties. For example,the interior of a recessed receptor location may include a coating whichconfers surface characteristics on the receptor location that enhanceassembly of a specific display element at or onto the receptor location.The display element may have combined size, shape and surfacecharacteristics complementary to the size, shape and surfacecharacteristics of the corresponding receptor location.

In some embodiments, display elements may be held in fixed spatialrelationship with respect to the substrate by one or more connectionsbetween the display elements and substrate. Connections between thedisplay elements and the substrate may provide structural or mechanicalstability or rigidity. They may also provide electrical, optical,acoustic, magnetic or other connections that provide for the transfer ofdata, power, or control signals. Connections between display elementsand substrate may conduct thermal energy, thus providing a heat sink,cooling, or heating, e.g., in order to provide a desired thermalenvironment. Control and power signals may be transmitted to displayelements by various means, including wireless transmissions, andassembly of display elements into arrays may be a separate process fromthe formation of control links to display elements. In some cases,direct physical connections between display elements may not be requiredto provide for the transmittal of power or control/data signals, and mayonly provide mechanical support and/or spatial positioning and/ororientation.

Connections between display elements and the substrate may be rigid orflexible. In some embodiments, mechanical connections may providestrength and structural integrity to the assembled array as a whole.Display element arrays for use in television screens or computermonitors may be formed on rigid and substantially planar substrates.However, in some applications of display element arrays, it may bedesirable for display element arrays to be formed on flexiblesubstrates. Display element arrays formed on non-planar rigid orsemi-rigid substrates may be used in some embodiments.

In some cases, the interaction between display elements and substrateused to produce self-assembly of display elements may be sufficientlystrong that display elements will be joined securely to the substratewithout any further connection being provided between the displayelements and substrate. In many cases, however, the association ofdisplay elements may not provide sufficiently secure connection of thedisplay elements for the intended application. In such cases, displayelements and substrate may be connected together by various methods.Mechanical connections may be formed through the use of variousadhesives, including self-fusing adhesives, similar to or includingself-fusing silicone adhesives, an example of which is 3M® Scotch™Self-Fusing Silicone Rubber Electrical Tape. They may also be formed bycausing the material of the display elements and substrate to fuse oradhere together, e.g. by electrostatic or magnetostatic attractionmeans. Such fusing or adhesion could be produced by applying heat, lightor other radiation (e.g., to produce a photochemical reaction), chemicaltreatment, pressure (for example, either steady or intermittentpressure, or ultrasonic pulses) to form connections between displayelements. Such connections may be based on melting or sintering ofdisplay element materials, chemical bonding, cross linking, and variousother processes, as known to those of skill in the relevant arts,exemplified by Gracius et al., Science, Vol. 280, pp. 1170-1172, Aug.18, 2000 and Zheng et al.; Proc. Natl. Acad. Sci., Vol. 101, No. 35, pp.12814-12817, Aug. 31, 2004, both of which are incorporated herein byreference.

In some embodiments, display elements may be held in fixed spatialrelationship with respect to other display elements by directconnections between adjacent display elements, in addition to or insteadof by connection of display elements to a substrate. Connections betweendisplay elements may provide structural or mechanical stability orrigidity. They may also provide electrical, optical, or otherconnections that provide for the transfer of data, power, or controlsignals between display elements and other display elements and/or asubstrate. Connections between display elements may conduct thermalenergy, thus providing a heat sink, cooling, or heating. Mechanicalconnections between adjacent display elements and between displayelements and substrate may be formed by adhesives of various types,depending on the material(s) used in the display elements. Mechanicalconnections may also be formed by causing the material of the displayelements themselves to bond or adhere together. Such bonding or adhesioncould be produced by applying heat, chemical treatment, pressure (forexample, either steady or intermittent pressure, or ultrasonic pulses)to form connections between display elements. Such connections may bebased on melting or sintering of display element materials, chemicalbonding, cross linking, and various other processes, as known to thoseof skill in the relevant arts. Electrical, magnetic, acoustic or opticalconnections may require the alignment of contact regions (which mayoccur simultaneously with self-organization of display elements toreceptor locations) and formation of an electrical or opticalconnection, by suitable processes as listed above or other processesknown to those of skill in the relevant arts. Electrical connections maypermit the transmittal of control, data, and/or power signals. In someembodiments, connections between display elements may include one ormore optical, magnetic, or acoustic connections between display elementsfor the transmittal of control or data signals. Mechanical connectionsbetween display elements may be formed by adhesives of various types,depending on the material(s) used in the display elements. Electrical oroptical connections may require the alignment of contact regions (whichmay occur simultaneously with self-organization of display elements) andformation of an electrical or optical connection, by suitable processesas listed above or other processes as will be known to those of skill inthe relevant arts, such as conductive epoxies, mating metal surfaces orsolder reflow.

According to certain embodiments, securing display elements distributedto receptor locations on a substrate in fixed relationship with respectto each other may be achieved by securing the display elements withrespect to the substrate. In some embodiments, display elementsdistributed to receptor locations on the substrate may be secured infixed relationship with respect to each other by securing each displayelement with respect to at least one other display element. In someembodiments, connections may be established for delivering controlsignals to drive emission of light by the secured display elements byforming a contact between each secured display element and electroniccircuitry on the substrate. Connections for delivering control signalsto drive emission of light by the secured display elements may beestablished by forming a wireless link between each secured displayelement and a remote driver. A wireless link may be established, forexample, by sending an activation signal keyed to a unique identifierfor each secured display element, with the unique identifier beingassociated with a location of the secured display element.Alternatively, a wireless link may be established by sending anactivation signal keyed to a specific location for each secured displayelement. The method may include providing a control signal to eachsecured display element to test the function of the secured displayelement.

Connecting display elements to the substrate may include applying heator light to the display elements, the substrate, or a binder contactingthe display elements, applying pressure to the display elements, orchemically, radiantly or electromagnetically treating the displayelements.

FIG. 15 illustrates several display elements 300, 302, and 304 attachedto a respective receptor site 306, 308, and 310 on substrate 312. Inthis exemplary embodiment, receptor sites 306, 308, and 310 are regionson surface 313 of substrate 312, having respective distinct surfacecharacteristics. Display element 300 includes a surface region 314 thatis complementary to region 306 on surface 313, display element 302includes a surface region 316 that is complementary to region 308 onsurface 313, and display element 304 includes a surface region 318 thatis complementary to region 310 on surface 313. Regions 306, 308, and 310and complementary surface regions 314, 316, and 318, are depicted inschematic form in FIG. 15, not intended to illustrate any specificsurface properties, but merely to indicate different complementarysurface properties. Complementary surface properties may include, butare not limited to, one or more of surface electric charge, surfaceenergy, magnetic properties, binding affinity of organic molecules andspecifically biomolecules (e.g., complementary nucleic acid sequences,protein, glycoprotein, amino acid or saccharide interactions,antibody-antigen interactions, etc.).

FIGS. 16-18 illustrate several exemplary display elements. In theembodiment shown in FIG. 16, display element 350 includes light-emittingelement 352 and carrier 354. Carrier 354 may include recess 356 intowhich the light-emitting element 352 is placed subsequent to manufactureof the light-emitting element and the carrier, as shown in FIG. 16. Inthis embodiment, display elements 350 include electronic circuitry 358.Power and control signals may be delivered to display element 350 from asubstrate on which it is mounted, via contacts 364 and 366. As depictedin FIG. 16, light-emitting element 352 may be formed separately fromcarrier 354. Light-emitting element 352 fits into recess 356 in carrier354, where contacts 360 on light-emitting element 352 and contacts 362in recess 356 form a connection by which signals used to activatelight-emitting element 352 to produce light can be delivered.Light-emitting element 352 and carrier 354 may be produced by standardfabrication techniques including, for example, injection molding of aplastic body around a semiconductor-based light-emitting element.

FIG. 17 depicts an alternative embodiment of a display element 400 inwhich light-emitting element 402 is formed integrally with carrier 404.Carrier 404 may be a silicon structure in which semiconductor-basedelectronic circuitry has been formed. Light-emitting element 402 may be,for example, a light-emitting diode or laser diode, either of which canbe formed in an integrated semiconductor device. Contacts 406 mayprovide for the transmission of power and/or control signals betweendisplay element 400 and a substrate or adjacent display element. In theembodiments of FIG. 17, the light-emitting element is formed integrallywith the carrier and no clear distinction can be made between displayelement, light-emitting element, and carrier, the carrier feature of thedisplay element residing in the surface characteristic of the externalportion. The body-forming material may itself include light-emittingproperties. For example, all or a portion of the body may be formed froma light-emitting material such as that used in organic LEDs.

In another embodiment, depicted in FIG. 18, a display element 450 mayinclude light-emitting element 452 and carrier 454. Carrier 454 may takethe form of a coating applied to the exterior of light-emitting element452. Carrier 454 may be applied to light-emitting element 452, forexample by dipping the light-emitting element 452 into a material thatwill form carrier 454, by spraying a material that will form carrier 454onto the light-emitting element, or by other methods known in the art.Carrier 454 may include or be formed of one or more materials with asurface property 456 that promotes self-organization of display element450 with other display elements.

In certain embodiments, a display element may include multiplelight-emitting elements. In the example of FIG. 19, a display element500 includes two light-emitting (or -modulating elements) 502 and 504,contained within carrier 506. Light-emitting elements 502 and 504 mayemit light of the same general color which, however, differs in terms ofwaveband or other characteristics. For example, light-emitting element502 may emit broad-waveband red light, while light-emitting element 504may emit red light in a narrow waveband. Alternatively, light-emittingelements 502 and 504 may be identical light-emitting elements that areincluded in duplicate to provide redundancy, so that if onelight-emitting element fails, the other may serve as a backup. Inanother alternative, light-emitting elements 502 and 504 may be twoidentical light-emitting elements such that display element 500 may emitlight in a broader range of light intensities than if it included only asingle light-emitting element. In still another embodiment,light-emitting elements 502 and 504 may emit light in bands havingdifferent central peaks. This may allow greater spectral coverage, oruse of less expensive components while still providing light in a usablerange. Display element 500 may also include shape, size, or surfacecharacteristics 508 that facilitate self-assembly of display element 500to a receptor location.

In a further embodiment depicted in FIG. 20, display element 550 is madeof two or more (in this example, three) sub-elements 552, 554, and 556that are assembled together prior to assembly of display element 550 tosubstrate 558. Assembly of display sub-elements 552, 554, and 556 toform display element 550 may be via a self-assembly process or byvarious other processes, as are known to those of skill in the relevantarts. Sub-elements 552, 554, 556 may include light-emitting elements560, 562, and 564, respectively, which may be of the same or differenttypes. In one useful combination, for example, light-emitting element560 may emit light in a red wavelength band, light-emitting element 562may emit light in a green wavelength band, and light-emitting element564 may emit light in a blue wavelength band. Other combinations ofmultiple light-emitting elements may be used to provide redundancy,greater range of intensities, enhanced spectral content, and so forth.Each display sub-element 552, 554, and 556 may include a respectiveshape, size or surface characteristic 566, 568, 570 that causes displayelement 550 to distribute to a receptor location 574 on substrate 558.Receptor location 574 may include a shape, size or surfacecharacteristic complementary to the combined shape, size or surfacecharacteristics 566, 568, and 570.

Various of the exemplary embodiments disclosed herein (e.g., in FIGS. 1and 4-10) include display elements arranged in regular, rectilinear N×Nor M×N arrays. However, as used herein, the term “display element array”applies not only to regular, rectilinear arrays, but also to arraysformed from various other arrangements of display elements, includingarrangements of display elements that are non-uniform with respect tovarious parameters, including, but not limited to spacing, orientation,size, and type of display elements. Display element arrays may includetwo or more distinct regions, configured so that within each region thedisplay element array is regular and uniform, but between regions andacross the display element array as a whole, there is a non-uniform,irregular distribution of display elements. Display element arrays mayalso include arrangements of display elements that are non-uniformoverall. Non-uniform distributions may include gradients with respect todisplay element size, color, etc., for example, running from one side ofa display element array to another, or from the center of a displayelement array to the edges. Non-uniform display element arrays may benon-uniform but have a statistical distribution of display elements oversome or all of the array. In certain embodiments, the spatialdistribution of display elements over an array may be random orquasi-random.

FIG. 21 illustrates an embodiment of a display element array 600 inwhich receptor locations of three different types 604, 606 and 608 aredistributed over substrate 602 in random or substantially randompattern. The distribution of receptor locations may bewell-characterized by various statistical measures. For example, thedistance between receptor locations of a particular type (e.g., thedistance between two receptor locations 604) may follow a normaldistribution with a known mean and standard deviation. In otherembodiments, receptor locations (and hence display elements in theassembled display element array) may have various distributions, and arenot limited to any particular distribution.

Display elements may be responsive to one or more control signals.Control signals may include electrical signals transmitted viaelectronic circuitry, electromagnetic signals transmitted to displayelements via a transmitter and received by a receiver (or transceiver),optical signals delivered via optical circuitry or electromagneticsignal, acoustic signals delivered via various paths, etc. A controlsignal may produce emission of light by a light-emitting elementdirectly (e.g., in the case of an electron beam, UV beam, or otherenergy impinging on a phosphor to cause emission of light) or a controlsignal may be processed by electronic or optical circuitry on thelight-emitting element to control light emission indirectly, in whichcase the control signal may initiate, stop, or otherwise modulate theemission of light by light-emitting elements.

A variety of approaches to selectively activating individual elements,or groups of elements may be implemented. In a straightforward N×N orM×N array of elements, conventional row and column addressing, such asthat found in many matrix array structures, such as LCDs, may beappropriate. The control electronics and tradeoffs for such addressingand selective activation are known to those of skill in the art.

The display may include electronic circuitry configured for carryingelectrical control signals to selected receptor locations on thesubstrate to control display elements at the selected receptorlocations. The display may also include optical circuitry configured forcarrying optical control signals to one or more selected receptorlocations on the substrate to control display elements and the selectedreceptor locations. In some embodiments, the display may also comprisean electromagnetic radiation source or charged particle beam projector,wherein each display element of the plurality of display elements isselectively activatable by directing the radiation source or chargedparticle beam projector toward the display element to activate thedisplay element. The “radiation source” or charged particle beamprojector may include an electron gun or an ultraviolet or infraredradiation source. Display elements may be selectively activatable byelectromagnetic energy directed onto the selected display elements atselected locations on the display. Control signals may includeelectromagnetic energy, e.g., ultraviolet radiation or an electron beam,an electrical signal, an optical signal, an acoustic signal, or variousother control signals, as known to those of skill in the relevant art.

In some embodiments, a method of controlling a multi-element display mayinclude transmitting a control signal including an element selectioncomponent and an activation signal component to a plurality of displayelements of a multi-element display. Each display element may have aunique identifier associated with it. The element selection componentmay include information identifying at least one selected displayelement to be controlled by the control signal. The activation signalcomponent may specify a desired operation of the selected displayelement(s). The control signal may be receivable by all display elementsof the plurality of display elements, but capable of producingactivation of only the selected display element to produce the desiredoperation. The identifying information may be an identification codethat uniquely identifies the display element. Alternatively, theidentifying information may be an address specifying the location of theselected display element in the display. In some embodiments, thecontrol signal may be a wireless control signal sent to the display froma remote location.

Connecting groups of associated display elements or individual displayelements to a substrate or to each other may include forming connectionsfor transmitting data or power. Such connections may include electrical,magnetic, optical or acoustic connections. As an alternative to directphysical (mechanical, electrical, or optical) connections, power, data,or control signals may be transmitted to display elements via remote orwireless connections, or by other means as described previously. Displayelements may include transmitters, receivers, or transmitter-receiver(transceiver) combinations for sending and/or receiving RF or othersignals. Power may be transmitted to display elements by variousmethods, including inductive coupling or power beaming, as well as viadirect electrical connections.

As discussed above, if the substrate includes both power and addresslines, then activating selected display elements in the assembleddisplay element array to produce a desired pattern may be performed in astraightforward manner, using addressing schemes as are well known tothose of skill in the relevant arts. In other embodiments, the substratemay provide power, but not control signals, to the display elements.Delivery of control signals to provide selective activation of thedisplay elements may be achieved by other means. An exemplary embodimentis depicted in FIG. 22, and corresponding method is shown in FIG. 23, inwhich selective control of display elements relies upon the performanceof a preliminary configuration process.

FIG. 22 illustrates a set-up for testing and configuring a displayelement array 650, which includes substrate 652 and at least two displayelements 654 and 656 distributed to receptor sites 658 and 660 insubstrate 652. Display element 654 includes an identification tag 670and logic 674, and display element 656 includes identification tag 672and logic 676. In the present example, identification tags 670 and 672are distinguishable from each other and may be uniquely identifiablerelative to other display elements in the array 650. In this example,identification tags 670 and 672 may be passive RFID tags responsive toselected patterns of RF radiation. In other embodiments, theidentification tags may be active RFID tags, or other devices orstructures capable of storing an identification number, code, or otheridentification information that identifies each display element.

Substrate 652 includes power connections 678, which supply power todisplay elements 654 and 656. Logic circuitry 674 in display element 654is configured to activate display element 654 to produce lightresponsive to an input signal, such as that from an RF transmitter, thatmatches unique identification tag 670. The identification informationrelating to each of the display elements may be determined a priori, ormay be gathered by systematically interrogating the array 650.

In one approach, under control of microprocessor 684, transmitter 680generates a series of RF signals coded to various different identifiers.If logic circuitry 674 in the identification tag 670 determines that oneof the RF signals matches the identification information in theidentification tag 670, the logic circuitry 674 activates the displayelement 654. Detector 682 detects activation of display element 654 andthe identification information corresponding to the identification tag670 is then stored in memory 684 of microprocessor based device 686. Asthe process is repeated for each of the RF signals in the sequence, thedata in the memory 684 eventually forms a mapping of the identificationtags 672 and others relative to their respective identificationinformation. In the future, when activation of a selected displayelement, e.g., display element 654, is desired, circuitry that drivesthe resulting display can selectively activate elements by retrievingthe corresponding identification information from the memory 684 andtransmitting to the selected display element, e.g., element 672, thecorresponding RF signal.

Note that, although the process above is described in connection with anexemplary embodiment employing RFID structures, other identificationstructures may also be appropriate. Electromagnetically responsiveelements that are responsive to electromagnetic radiation of variousother frequencies, for example, microwave and sub-RF frequencies, may beused as identification structures or tags. Electromagneticallyresponsive elements for use as identification structure are not limitedthose that are responsive to any particular frequency range. In otherembodiments, each display element may include an optically responsivestructure that responds selectively to its respective identificationinformation. In still another approach, each of the display elements mayinclude indicators that are machine-readable or otherwise readilydeterminable. With use of machine vision or other readily implementedapproaches, the relative locations of the display elements may bedetermined.

FIG. 23 depicts the steps of a process for forming a self-assembledarray and establishing the location of specific display elements withinthe self-assembled array, as described in connection with FIG. 22. Thisprocess may be used in systems in which display elements have individualidentifiers (e.g., identification codes or numbers) and are controlledby wireless control signals, though modifications of the approach may beapplied in systems using other types of connections. The location ofspecific display elements must be determined after the display elementshave self-assembled into their respective receptor locations in thearray. At step 702, display elements 1 through N are allowed toself-assemble into their corresponding receptor locations. At step 704,display elements 1 through N are secured in fixed relationship to theirreceptor locations. Subsequent steps are carried out for displayelements 1 to N, as controlled at step 706, or by an equivalent controlloop. At step 708, a wireless control signal containing the instruction“Activate display element n” is sent to all display elements, to produceactivation of element n. At step 710, the location of activated displayelement n, designated by loc(n), is detected. At step 712, loc(n) isstored in the memory of a controller, along with the identifier n.Process control returns to step 706, and steps 708 through 712 arerepeated for all values of n between 1 and N. When steps 708 through 712have been repeated for all values of n, training or configuration of thesystem is complete, and use of the system may commence as represented bystep 714. At step 714, a display element at a desired location loc(n) isactivated by sending a wireless control signal containing theinstruction “Activate display element n.” Suitable wireless controlsignals may be sent out for as long as desired to activate one or moredisplay elements at a time in a desired pattern.

FIG. 24 illustrates a further embodiment of an assembled display elementarray, in which display elements 800 and 802 are assembled into receptorlocations 804 and 806 in substrate 808. Display elements 800 and 802 areonly two of a larger number of display elements located in substrate 808but not shown in FIG. 24. In this embodiment, substrate 808 providesmechanical support, but may not contain control or power transmissionlines. Display element 800 includes transceiver 810, microprocessor 812,identifier 814, and memory 816. Similarly, display element 802 includestransceiver 818, microprocessor 820, identifier 822, and memory 824.Following self-assembly of display elements 800 and 802 into substrate808, display elements may transmit identification signals with theirrespective transceivers 810 or 818 to other display elements, andreceive identification signals sent from other display elements. Basedupon signal strength, latency, or other distance-dependent variables,the relative position of each display element with respect to otherdisplay elements, and hence with respect to the display element array asa whole, may be determined by code run by microprocessor 812 or 820.Location information may be stored in a memory 816 or 824, respectivelyon display elements 800 and 802. A display control signal containing alocation-based element selection component and an activation signalcomponent may be transmitted by a transmitter 830 and received bytransceiver 810 and 818. If the element selection component matches thelocation information stored in the memory of a particular displayelement, activation of the display element is then controlled inaccordance with the activation signal component. The display controlmethods described in connection with FIGS. 22-24 are merely exemplary,and various other methods known to those of skill in the art ofcontrolling self-assembled display element arrays may be developed andused in connection with display element arrays as disclosed herein.

Self-organizing and/or self-assembling display element arrays asdisclosed herein may find application in a wide variety of devices andsystems. For example, FIG. 25 depicts application of a self-assemblingdisplay element array 1000 in computer monitor 1002. As another example,FIG. 26 depicts application of a self-assembling display element array1010 in a television screen 1012. It is increasingly the case that thereis little distinction between television screens and computers monitors,as televisions include more interactive capabilities, and televisionscreens include capabilities for displaying images in multiple windows,displaying menu options, and so forth.

FIG. 27 illustrates the use of self-assembled display element arrays ona sign 1020. The example presented in FIG. 27 includes a static displayportion 1022 that may be configured to display a static image 1024 (inthis case, the text “Coffee Shop & Billiards”), while dynamic displayportion 1026 may be configured to display a message or image 1028 thatmay be changed at intervals. If desired, the dynamic display portion maydisplay a continuously changing message or image (e.g., scrolling textor animated image). Static display portion 1022 and dynamic displayportion 1026 may differ with regard to type and distribution of displayelements, or with regard to the control signals used to control thedisplay elements. Signs (and related displays, such as labels,advertisements, billboard, etc., which may also incorporate embodimentsof the present invention) may be entirely static, entirely dynamic ormixed-modal, depending on their intended use. Sign 1020 may includebattery 1030 and control circuitry 1032 mounted in or on sign 1020 fordriving operation of static display portion 1022 and dynamic displayportion 1024.

Self-assembled display element arrays may also be used on items ofapparel, or other decorative or functional items formed of flexiblefabric or material. As an example, FIG. 28 illustrates the use of aself-assembled display element array on a baseball cap 1050. Baseballcap 1050 includes panel 1052 containing display element array 1054,which may be formed on a flexible substrate. Text, images, or patterns,which may be either static or dynamic, may be displayed on displayelement array 1054. In the example shown in FIG. 28, display elementarray 1054 displays text 1056, reading “GO TEAM!” Display element array1054 may be powered by various methods. As shown in FIG. 28, a smallbattery 1058 may be mounted on cap 1050 in an inconspicuous location(e.g., in the interior of cap 1050) and connected to display elementarray 1054 via lead 1064. Alternative power supplies may be usedinstead, e.g., a solar cell. Controller 1060, which may be an ASIC- or amicroprocessor-based device, may be mounted on cap 1050 and connectedvia one or more data-lines 1062 to display element array 1054 to driveoperation of display element array 1054.

FIG. 29 illustrates the use of a self-assembled display element assemblyon a decorative item having a non-planar substrate: in this example, avase 1200 bearing a panel 1202 displaying the message “Get Well Soon!”.The message “Get Well Soon!” may alternate with one or more othermessages or images, may scroll across the panel, may flash, or mayproduce various other visual effects. Such variations of displays may beapplied to any other embodiments in which a dynamic display elementarray is used, including but not limited to the examples presentedherein. Vase 1200 may incorporate a battery or other power supply andcontrol circuitry, as discussed in connection with the baseball capembodiment depicted in FIG. 28.

Self-assembling display element arrays may be used in virtually anysetting in which it is desired to graphically display static or dynamictext, images, or patterns on a surface. As discussed previously, dynamicdisplays may be varied at intervals (for example, dynamic displayportion 1026 in FIG. 27 may be changed from “Closed—Come back Soon” to“Open—Come on In”), or may be varied continuously to display scrollingor flashing text, animated graphic, or various other dynamic displays asmay be devised by those of skill in the relevant arts. Display elementsmay be of a wide range of sizes, and display element arrays or displaysformed from such display elements may be of a wide range of sizes andresolutions, depending on intended application and construction methodand materials. Text, images, and patterns formed through the use of suchdisplays may be informative, decorative, or functional. Such displaysmay be used in or on a wide variety of decorative and/or functionalitems, to convey information or to change the appearance of an item in afunctional manner (e.g., camouflage or visual signature-reduction on avehicle or item of clothing), or to present a desired decorativeappearance on various items (objects, items of apparel, etc., signs,labels, artwork.)

FIGS. 30A-30D illustrate the manufacture of a display having severalregions containing self-assembled display element arrays of differenttypes. In the example depicted in FIGS. 30A-30D, display 1300 includes afirst display region 1302 on substrate 1301, which defines a faceportion of a “smiley face”. First display region 1302 may include afirst type of receptor locations. Two eye portions 1306 and mouthportion 1308 may include a second type of receptor locations. Backgroundregion 1314, which forms a background to the smiley face, includes athird type of receptor locations. In FIG. 30B, a mixture of displayelements 1318 is disposed on substrate 1301 from dispenser 1330. Mixture1318 includes first, second and third display element types, 1320, 1322,and 1324, respectively, which are depicted in enlarged view in FIG. 30C.Mixture 1318 includes first, second and third display element types,1320, 1322, and 1324, in quantities sufficient to fill respectivereceptor locations in first display region 1302, eye portions 1306,mouth portion 1308, and background region 1314. First display elementtype 1320, second display element types 1322, and third display elementtypes 1324 may differ from each other in one or more characteristics.Following loading of display elements onto substrate 1301, the systemmay be agitated to cause the display elements to self-organize intotheir respective receptor locations. FIG. 30D illustrates display 1300following assembly of display elements 1320 into their respectivereceptor locations in first display region 1302, display elements 1322into their respective receptor locations in eye portions 1306 and mouthportion 1308, and display elements 1324 into their respective receptorlocations in background region 1314.

Each display region may include receptor locations for a single type ofdisplay element, as depicted in FIGS. 30A-30D. For example, the firstdisplay region 1302 may include receptor locations for display elementsof a first color (e.g., yellow), while the background regions mayinclude receptor locations for display elements of a second color (e.g.,blue). Alternatively, display regions may include receptor locations formultiple types of display elements, for example, the first displayregion 1302 may include receptor locations for orange and yellow displayelements, while background region 1314 may include receptor locationsfor green and blue display elements. As another alternative, differentregions of the display may include receptor locations for displayelements of the same types in different proportions, for example, thefirst region may include one-third receptor locations for red displayelements, one-third receptor locations for blue display elements, andone-third receptor locations for green display elements, while a seconddisplay region may include one-half receptor locations for red displayelements, and one-quarter each of receptor locations for blue displayelements and green display elements.

Display elements may differ by other characteristics than color, e.g.,size, power consumption, spectral waveband, etc., and may differ by oneor by multiple characteristics. The choice of display elements used ineach region may be based on the text, pattern, or image that is to bedisplayed. If the display is intended to display a fixed pattern (e.g.,the smiley face depicted in FIGS. 30A-30D), the display elementcharacteristics may be selected to be suitable for the pattern. Forexample, the face portion of the smiley face may be yellow, and thebackground blue. The eyes and mouth portions may be black (in which casethere may be no need to provide display elements that emit light inthese portions). In the sign as depicted in FIG. 27, static displayportion 1022 may include a first mixture of display elements suitablefor displaying the intended static image or text, while the lowerportion may include a different assortment of display elements, e.g.,larger display elements in a single color, suitable for displaying theintended basic text but insufficient for displaying an image or moreelaborate text.

FIG. 31 illustrates how display elements may be delivered to a substratesurface at two or more locations, by the use of multiple deliverydevices. A first quantity of display elements 1450 is delivered to firstlocation 1452 on substrate 10 from first delivery device 1454. A secondquantity of display elements 1456 is delivered to second location 1458on substrate 10 from second delivery device 1460. Substantially the sameresult could be obtained by using a single delivery device and movingthe delivery device (which may be, for example, a nozzle, spout, inkjet,pressure jet, sprayer, etc.) with respect to the substrate, or movingthe substrate with respect to the delivery device. By deliveringdifferent display elements (i.e., different types of display elements ormixtures of the same types of display elements in different proportions)at different locations, a spatially non-uniform distribution of displayelements on the substrate may be obtained.

FIGS. 32A and 32B illustrate a method of forming a non-uniformdistribution of display elements on a substrate. In FIG. 32A, a firstquantity of display elements 1400 (which may include a first mixture ofdisplay elements) is disposed onto substrate 10 from dispenser 1402during a first time interval t₁. First quantity of display elements 1400may have physical characteristics (size, shape, surface properties,density, etc.) that cause first quantity of display elements 1400 tospread out onto substrate 10 or may be in a mixture (e.g., with aliquid, gas or solid) that confers suitable spreading properties tofirst quantity of display elements 1400. In FIG. 32B, a second quantity(type or mixture) of display elements 1404 is disposed onto substrate 10from dispenser 1402 during a second time interval t₂. Second quantity ofdisplay elements 1404 spreads out onto substrate 10, causing furtheroutward spreading of first quantity of display elements 1400. Theapproach illustrated in FIGS. 32A and 32B exemplifies how a spatiallynon-uniform distribution of display elements on a substrate may beobtained by distributing different types or mixtures of display elementsto the same location of a substrate at different times.

FIGS. 33A-33C illustrate a method of replacing defective ornon-functional display elements. Display elements may be considereddefective if they are partially or fully non-functional, functional butnot connected properly, not positioned properly, or of the wrong typefor the position in the array. The method may apply to single displayelements or groups of display elements. The method may be used duringthe initial manufacture of the display element array, in connection withtesting or troubleshooting, or may be adjusted for use post-manufacture,e.g., in the repair of damaged or worn out display element arrays. FIG.33A illustrates display element array 1500, made up of two differenttypes of display elements 1502 and 1504, assembled into receptorlocations 1506 and 1508, respectively, on substrate 1510. Shaded displayelement 1512, assembled into receptor location 1514, is a defectivedisplay element of the same type as display elements 1504.

Non-functional display elements in a display may be detected by variousmethods, during and/or subsequent to the manufacture of the display. Forexample, a CCD camera may be used to detect activation of displayelements. Display elements may be activated in a specified pattern;differences between the detected and expected pattern may indicatenon-functional display elements. Activation of display elements mayoccur sequentially, simultaneously, or in any other pattern that isconvenient for the particular display being tested. Different elementsmay be differentiated by time sequential activation and detection, colorspecific activation and detection, and so forth. Alternatively,activation of display elements may be determined by any signal thatcorrelates with display element activation. For example, electricalcorrelates such as voltage drop or current may be measured as a means ofdetermining activation of a display elements. Detection of electricalcorrelates may be performed with circuitry built into the displaysubstrate or by separate test equipment.

FIG. 33B depicts display element array 1500 following removal ofdefective display element 1512 from receptor location 1514, leaving anempty receptor location 1514. Suitable methods for removing displayelements from an assembled array will depend on the size and type ofdisplay elements, and will be known by those of skill in the art. In thecase of small display elements, a moistened probe, for example, may betouched to the assembled array in the region of interest, and displayelements may adhere to the probe by surface tension so they may belifted from the assembled array. In other embodiments, adhesives,suction, magnetic forces, and various other forces may be used to lift aselected display element or group of display elements from a substrate.In some embodiments, defective display elements may be decoupled fromtheir respective receptor locations prior to removal, through the use ofheating, light, moisture, chemicals, electrical or magnetic fields, orvarious other methods, which will depend on the manner in which thedisplay element(s) in question are held in place. In some embodiments,removal of display elements from a substrate may be possible only duringinitial manufacture steps, while in other embodiments removal of displayelements from a substrate may be possible at various points aftermanufacture of the display.

Following removal of one of more defective display elements, emptyreceptor locations may be filled by replacement display elements byperforming a procedure like that used initially to distribute displayelements to receptor locations, e.g., as depicted and described in FIGS.2-10. FIG. 33C illustrates display element array 1600 following a repairprocess. Receptor location 1514 in substrate 1510 has been filled byreplacement display element 1516.

FIG. 34 outlines the steps of a method as illustrated in FIGS. 33A-33C.At step 1602, a display that includes a substrate and a plurality ofdisplay elements distributed to receptor locations on the substrate istested to detect at least one defective display element. At step 1604,the defective display element is removed from a receptor location in thedisplay substrate, to leave at least one vacant receptor location. Atstep 1606, a plurality of display elements are disposed on thesubstrate. Each display element may have shape, size, or surfacecharacteristics complementary to the shape, size, or surfacecharacteristics of at least one vacant receptor location. At step 1608,relative movement is induced between the display elements and thesubstrate sufficient to cause at least one display element to selfassemble into the at least one vacant receptor location. Depending onthe particular embodiment, following the self assembly process of step1608, display elements may be secured sufficiently strongly to thesubstrate, or, in some embodiment, a further attachment step may be usedto secure one or more display element in place at respective receptorlocations.

With regard to the hardware and/or software used in the control ofdisplays according to the present image, and particularly to the controlof light generation by display elements within such displays, thosehaving skill in the art will recognize that the state of the art hasprogressed to the point where there is little distinction left betweenhardware and software implementations of aspects of such systems; theuse of hardware or software is generally (but not always, in that incertain contexts the choice between hardware and software can becomesignificant) a design choice representing cost vs. efficiency orimplementation convenience tradeoffs. Those having skill in the art willappreciate that there are various vehicles by which processes and/orsystems described herein can be effected (e.g., hardware, software,and/or firmware), and that the preferred vehicle will vary with thecontext in which the processes are deployed. For example, if animplementer determines that speed and accuracy are paramount, theimplementer may opt for a hardware and/or firmware vehicle;alternatively, if flexibility is paramount, the implementer may opt fora solely software implementation; or, yet again alternatively, theimplementer may opt for some combination of hardware, software, and/orfirmware. Hence, there are several possible vehicles by which theprocesses described herein may be effected, none of which is inherentlysuperior to the other in that any vehicle to be utilized is a choicedependent upon the context in which the vehicle will be deployed and thespecific concerns (e.g., speed, flexibility, or predictability) of theimplementer, any of which may vary. Those skilled in the art willrecognize that optical aspects of implementations will requireoptically-oriented hardware, software, and or firmware.

The foregoing detailed description has set forth various embodiments ofthe devices and/or processes via the use of block diagrams, flowcharts,and/or examples. Insofar as such block diagrams, flowcharts, and/orexamples contain one or more functions and/or operations, it will beimplicitly understood by those with skill in the art that each functionand/or operation within such block diagrams, flowcharts, or examples canbe implemented, individually and/or collectively, by a wide range ofhardware, software, firmware, or virtually any combination thereof. Inone embodiment, several portions of the subject matter described hereinmay be implemented via Application Specific Integrated Circuits (ASICs),Field Programmable Gate Arrays (FPGAs), digital signal processors(DSPs), or other integrated formats. However, those skilled in the artwill recognize that some aspects of the embodiments disclosed herein, inwhole or in part, can be equivalently implemented in standard integratedcircuits, as one or more computer programs running on one or morecomputers (e.g., as one or more programs running on one or more computersystems), as one or more programs running on one or more processors(e.g., as one or more programs running on one or more microprocessors),as firmware, or as virtually any combination thereof, and that designingthe circuitry and/or writing the code for the software and/or firmwarewould be well within the capabilities of one of skill in the art inlight of this disclosure. In addition, those skilled in the art willappreciate that certain mechanisms of the subject matter describedherein are capable of being distributed as a program product in avariety of forms, and that an illustrative embodiment of the subjectmatter described herein applies equally regardless of the particulartype of signal bearing media used to actually carry out thedistribution. Examples of a signal bearing media include, but are notlimited to, the following: recordable type media such as floppy disks,hard disk drives, CD ROMs, digital tape, and computer memory; andtransmission type media such as digital and analog communication linksusing TDM or IP based communication links (e.g., links carryingpacketized data).

In a general sense, those skilled in the art will recognize that thevarious aspects described herein which can be implemented, individuallyand/or collectively, by a wide range of hardware, software, firmware, orany combination thereof can be viewed as being composed of various typesof “electrical circuitry.” Consequently, as used herein “electricalcircuitry” includes, but is not limited to, electrical circuitry havingat least one discrete electrical circuit, electrical circuitry having atleast one integrated circuit, electrical circuitry having at least oneapplication specific integrated circuit, electrical circuitry forming ageneral-purpose computing device configured by a computer program (e.g.,a general-purpose computer configured by a computer program which atleast partially carries out processes and/or devices described herein,or a microprocessor configured by a computer program which at leastpartially carries out processes and/or devices described herein),electrical circuitry forming a memory device (e.g., forms of randomaccess memory), and/or electrical circuitry forming a communicationsdevice (e.g., a modem, communications switch, or optical-electricalequipment).

Those skilled in the art will recognize that it is common within the artto describe devices for displaying or otherwise presenting informationin the fashion set forth herein, and thereafter use standard engineeringpractices to integrate such described devices and/or processes intodisplays or other light-emitting or -modulating devices as exemplifiedherein. That is, at least a portion of the devices and/or processesdescribed herein can be integrated into a display or otherlight-emitting or -modulating device containing system via a reasonableamount of experimentation.

Those having skill in the art will recognize that such systems generallyinclude one or more of a memory such as volatile and non-volatilememory, processors such as microprocessors and digital signalprocessors, computational-supporting or associated entities such asoperating systems, user interfaces, drivers, sensors, actuators,applications programs, one or more interaction devices, such as dataports, control systems including feedback loops and control implementingactuators (e.g., devices for sensing position and/or velocity and/oracceleration or time-rate-of-change thereof; control motors or actuatorsfor moving and/or adjusting components and/or quantities). A typicaldisplay system may be implemented utilizing any suitable availablecomponents, such as those typically found in appropriatecomputing/communication systems and/or light-emitting systems, combinedwith standard engineering practices.

The foregoing-described aspects depict different components containedwithin, or connected with, different other components. It is to beunderstood that such depicted architectures are merely exemplary, andthat in fact many other architectures can be implemented which achievethe same functionality. In a conceptual sense, any arrangement ofcomponents to achieve the same functionality is effectively “associated”such that the desired functionality is achieved. Hence, any twocomponents herein combined to achieve a particular functionality can beseen as “associated with” each other such that the desired functionalityis achieved, irrespective of architectures or intermediate components.Likewise, any two components so associated can also be viewed as being“operably connected”, or “operably coupled”, to each other to achievethe desired functionality.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be obvious to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from this subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true spirit and scope of this subject matter describedherein. Furthermore, it is to be understood that the invention isdefined by the appended claims. It will be understood by those withinthe art that, in general, terms used herein, and especially in theappended claims (e.g., bodies of the appended claims) are generallyintended as “open” terms (e.g., the term “including” should beinterpreted as “including but not limited to,” the term “having” shouldbe interpreted as “having at least,” the term “includes” should beinterpreted as “includes but is not limited to,” etc.). It will befurther understood by those within the art that if a specific number ofan introduced claim recitation is intended, such an intent will beexplicitly recited in the claim, and in the absence of such recitationno such intent is present. For example, as an aid to understanding, thefollowing appended claims may contain usage of the introductory phrases“at least one” and “one or more” to introduce claim recitations.However, the use of such phrases should NOT be construed to imply thatthe introduction of a claim recitation by the indefinite articles “a” or“an” limits any particular claim containing such introduced claimrecitation to inventions containing only one such recitation, even whenthe same claim includes the introductory phrases “one or more” or “atleast one” and indefinite articles such as “a” or “an” (e.g., “a” and/or“an” should typically be interpreted to mean “at least one” and/or “oneor more”); the same holds true for the use of definite articles used tointroduce claim recitations. In addition, even if a specific number ofan introduced claim recitation is explicitly recited, those skilled inthe art will recognize that such recitation should typically beinterpreted to mean at least the recited number (e.g., the barerecitation of “two recitations,” without other modifiers, typicallymeans at least two recitations, or two or more recitations).Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” is used, in general such a constructionis intended in the sense of one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, and C”would include but not be limited to systems that have A alone, B alone,C alone, A and B together, A and C together, B and C together, and/or A,B, and C together). In those instances where a convention analogous to“at least one of A, B, or C, etc.” is used, in general such aconstruction is intended in the sense of one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, or C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together).

Although the methods, devices, systems and approaches herein have beendescribed with reference to certain preferred embodiments, otherembodiments are possible. As illustrated by the foregoing examples,various choices of display element and substrate configuration may bewithin the scope of the invention. As has been discussed, the choice ofsystem configuration may depend on the intended application of thesystem, the environment in which the system is used, cost, personalpreference or other factors. Display design, manufacture, and controlprocesses may be modified to take into account choices of displayelement components and configuration, and such modifications, as knownto those of skill in the arts of display design and construction, mayfall within the scope of the invention. Therefore, the full spirit orscope of the invention is defined by the appended claims and is not tobe limited to the specific embodiments described herein.

1. A method of forming a display, comprising: a) disposing a pluralityof display elements, each comprising a light-modulating element and acarrier containing said light-modulating element, on a substrate; b)inducing relative motion in said display elements and said substratesufficient to cause at least a portion of said display elements todistribute to receptor locations on said substrate; c) securing displayelements distributed to receptor locations on said substrate in fixedrelationship with respect to each other; and d) establishing connectionsfor providing control signals to secured display elements to drivemodulation of light by said secured display elements. 2.-7. (canceled)8. The method of claim 1, including controlling an environmentalcondition to promote distribution of said display elements to receptorlocations on said substrate.
 9. The method of claim 1, wherein disposinga plurality of display elements on a substrate includes disposing afirst subset of display elements and a second subset of display elementson said substrate, wherein each display element in said first subsetincludes a light-modulating element of a first type contained in acarrier having a first shape, size or surface characteristic and eachdisplay element in said second subset includes a light-modulatingelement of a second type contained in a carrier having a second shape,size or surface characteristic, and wherein said substrate includes afirst subset of receptor locations having a first complementary shape,size or surface characteristic that facilitates distribution of displayelements of said first subset to said first subset of receptorlocations, and a second subset of receptor locations having a secondcomplementary shape, size or surface characteristic that facilitatesdistribution of display elements of said second subset to said secondsubset of receptor locations. 10.-15. (canceled)
 16. The method of claim1, including providing a control signal to each said secured displayelement to test the function of said secured display element.
 17. Amethod of forming a display, comprising: a) introducing a first set ofdisplay elements, each having a first shape, size or surfacecharacteristic and including a light-modulating element of a first type,onto a substrate; b) inducing relative motion in said display elementsin said first set and said substrate sufficient to cause at least aportion of said display elements in said first set to distribute into afirst plurality of receptacles on said substrate, said first pluralityof receptacles having a first complementary shape, size or surfacecharacteristic that is complementary to said first shape, size orsurface characteristic; c) removing display elements in said first setthat have not distributed into receptacles in said first plurality ofreceptacles; d) introducing a second set of display elements, having asecond shape, size or surface characteristic and including alight-modulating element of a second type, onto said substrate; e)inducing relative motion in said display elements in said second set andsaid substrate sufficient to cause at least a portion of said displayelements in said second set to distribute into a second plurality ofreceptacles on said substrate, said second plurality of receptacleshaving a second complementary shape, size or surface characteristic thatis complementary to said second shape, size or surface characteristic;f) removing display elements in said second set that have notdistributed into receptacles in said second plurality of receptacles;and g) connecting display elements distributed into receptacles on saidsubstrate to said substrate. 18.-46. (canceled)
 47. A displaycomprising: a) a substrate comprising a first plurality of receptorlocations of a first type and a second plurality of receptor locationsof a second type arranged on said substrate in a repeating patternaccording to type, each receptor location of said first type comprisinga first surface characteristic and each receptor location of said secondtype comprising a second surface characteristic; b) a plurality ofdisplay elements of a first type mounted on said substrate at said firstplurality of receptor locations, each display element of said first typecomprising a surface characteristic adapted to operate cooperativelywith said first surface characteristic to facilitate self-assembly ofsaid first display element type with said first receptor location type;and c) a plurality of display elements of a second type mounted on saidsubstrate at said second plurality of receptor locations, and eachdisplay element of said second type comprising a surface characteristicadapted to operate cooperatively with said second surface characteristicto facilitate self-assembly of said second display element type withsaid second receptor location type.
 48. The display of claim 47, whereindisplay elements of said first type emit light that differs from lightemitted by display elements of said second set by one or more parametersincluding wavelength band envelope, spectral width, power, intensity,brightness, irradiance, spatial or temporal emission pattern,polarization, response speed, pulse format, or linearity.
 49. Thedisplay of claim 47, further comprising circuitry configured forconveying control signals to one or more selected receptor locations onsaid substrate to control display elements at said selected receptorlocations. 50.-56. (canceled)
 57. The display of claim 47, wherein atleast one display element of said first plurality and said secondplurality includes a unique identifier. 58.-59. (canceled)
 60. Themethod of claim 1, wherein each said carrier includes at least oneshape, size or surface characteristic including at least one of anelectrostatic charge characteristic, a magnetostatic chargecharacteristic, a surface energy characteristic, an electriccharacteristic, a magnetic characteristic, or a binding affinity of atleast one biomolecule, and wherein said relative motion is sufficient tocause each display element of said at least a portion of said displayelements to distribute to a receptor location on said substrate having acomplementary shape, size or surface characteristic.
 61. The method ofclaim 1, including securing display elements distributed to receptorlocations on said substrate in fixed relationship with respect to eachother by at least one of securing said display elements distributed toreceptor locations on said substrate with respect to said substrate andsecuring said display elements distributed to receptor locations on saidsubstrate with respect to one or more other display elements.
 62. Themethod of claim 1, including establishing connections for deliveringcontrol signals to drive modulating of light by said secured displayelements by forming a wireless link between at least one said secureddisplay element and a remote driver by at least one of sending anactivation signal keyed to a unique identifier associated with alocation of said at least one secured display element, or sending anactivation signal keyed to a specific location for said at least onesecured display element.
 63. The display of claim 47, wherein at leastone of said first surface characteristic and said second surfacecharacteristic comprises a shape characteristic, an electrostaticcharacteristic, a magnetostatic characteristic, a surface energycharacteristic, an electromagnetic characteristic, or a coating of atleast one biomolecule selected from at least one of an amino acidsequence, a nucleotide sequence, a saccharide sequence, a protein, and aglycoprotein.